Doosan A2300 Service Manual
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Doosan A2300 Service Manual

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SB4106E01
Service Manual
A2300 Diesel Engine
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5

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Summary of Contents for Doosan A2300

  • Page 1 SB4106E01 Service Manual A2300 Diesel Engine D15S-5, D18S-5, D20SC-5 G15S-5, G18S-5, G20SC-5 GC15S-5, GC18S-5, GC20SC-5...

  • Page 3: Important Safety Information

    If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 5: Table Of Contents

    Index Introduction Air System About the Manual............5 Air System Flow ............98 How to Use the Manual ..........5 Diagnosing Air System Malfunctions......99 Generic Symbols............6 Air Flow Restriction ..........99 Definition of Terms .............7 Damage from Non-Filtered Air .......100 Illustrations ..............8 Pressure Side Air Leaks.........100 Exhaust Leaks............101 Malfunctioning Turbocharger........101...

  • Page 6: Index

    Base Engine Components Balancer-Remove ..........221 Balancer-Install ............222 Operation and Description ........148 Engine Replacement and Testing Cylinder Head and Valve Train ......149 Front Gear Housing and Gear Train ......150 Front Crankshaft Seal ..........150 Engine Replacement..........223 Camshaft, Tappets and Push Rods .......150 Engine Removal.............224 Flywheel Housing and Flywheel ......151 Engine Installation..........225...

  • Page 7: Introduction

    Introduction About the Manual The procedures in this manual were developed for an in-chassis environment. The information has been grouped by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each section subdivides the instructions for the various components of the system. Wrench sizes and special tools are identified in the procedures as needed.

  • Page 8: Generic Symbols

    Generic Symbols The following group of symbols has been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below. Warning – Serious personal injury or extensive property damage can result if the warning instructions are not followed.

  • Page 9: Definition Of Terms

    Definition of Terms The following is a list of guidelines for each procedure in the “repair Sections” of the Troubleshooting and Repair Manual. The procedure will be given first; followed by a definition o the step or steps involved. Check Examine a component or system for damage, excessive wear, accuracy, safety, or performance.

  • Page 10: Illustrations

    Illustrations The illustrations used in the Diagnosis Sections of this manual are intended to give an example of a problem, show what to look for and where to look for the problem. Most of the illustrations are generic and might not look exactly like the engine or parts used in your application. Some illustrations contain symbols to indicate an action required and an acceptable or unacceptable condition.

  • Page 11: General Engine Information

    General Engine Information External Engine Components The pictures which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. Note: The pictures are only a reference to show a typical engine. Exhaust Side [Naturally Aspirated] Intake Side [Naturally Aspirated] 1.
  • Page 12 Exhaust Side [Turbocharged] Intake Side [Turbocharged] 1. Fuel Filter 5. Dipstick 1. Turbocharger 5. Starting Motor 2. Crankshaft Pulley 6. Oil Cooler 2. Alternator 6. Turbocharger Oil Tube 3. Cooling Fan 7. Fuel Injection Pump 3. Thermostat Housing 7. Oil Fill Cup 4.

  • Page 13: Engine Specifications

    Engine Specifications Engine Model A2300 General Engine Data Naturally Aspirated Engine Weight(Dry) Less Flywheel and Electronics 169 kg [373 lb] Compression Ratio 21:1 Bore [mm/inch] 88 [3.46] Stroke [mm/inch] 94 [3.7] Displacement [ℓ/in3] 2.29 [139] Firing Order 1-3-4-2 Intake 0.3 mm [0.012 in]...

  • Page 14: Engine Diagrams

    Troubleshooting Logic Engine Diagrams A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted to troubleshooting and repairing that particular system. The diagrams depict flow through the various engine systems. The information and configuration of the components illustrated in the drawings are of a general nature.

  • Page 15: Troubleshooting Logic(List Of Symptoms)

    Troubleshooting Logic Page List of Symptoms Alternator Not Charging or Insufficient Charging Coolant Loss Coolant Temperature Above Normal Coolant Temperature Below Normal Compression Knocks Contaminated Coolant Contaminated Lube Oil Engine Cranks But Will Not Start – No Smoke From Exhaust Engine Hard to Start Or Will Not Start –...
  • Page 16 Engine Will Not Crank or Cranks Slowly Cause Correction Remove the Starting Motor and Check for Starting Motor Operating But Not Broken Teeth on the Flywheel or Broken Cranking the Engine Starting Motor Spring. Refer to Page 138 Bar the Engine to Check for Rotational Crankshaft Rotation Restricted Resistance.
  • Page 17 Engine Cranks But Not Start – No Smoke From Exhaust Cause Correction No Fuel in Supply Tank Check/Replenish Fuel Supply Check for Loose Wires and Verify that the Electrical or Manual Fuel Valve is Functioning. Check to be sure Shutdown Not Open Manual Shut Off Lever is in the Run Position.
  • Page 18 Engine Hard To Start Or Will Not Start – Smoke From Exhaust Cause Correction The Fuel Control Lever on the Bosch VE Pump Must be Moved to One-Half Travel. Incorrect Starting Procedure The Fuel Shut Off Control Must Be in the Run Position.
  • Page 19 Engine Hard To Start Or Will Not Start – Smoke From Exhaust (Continued) Cause Correction Verify by Operating the Engine with Clean Contaminated Fuel Fuel from a Temporary Tank. Drain and Flush Fuel Supply Tanks. Visually Check Fuel Delivery With an Worn or Malfunctioning Injection Externally Connected Injector to one of the Pump...
  • Page 20 Engine Starts But Will Not Keep Running Cause Correction Engine Starting Under Load Disengage Driven Units. Idle Speed Too Low For Adjust the Idle Speed. Accessories Refer to Page 73 Visually Check for Exhaust Restriction and Intake Air or Exhaust System Inspect the Air Intake.
  • Page 21 Surging (Speed Change) Cause Correction If the Condition Occurs at Idle, the Idle Speed is Set Too Low for Adjust the Idle. Refer to Page 73 Accessories Inspect/Correct Leaks in the Pressure High Pressure Fuel Leak Lines. Fittings, Injector Sealing Washers or Delivery valves.
  • Page 22 Rough Idle (Irregularly Firing Or Engine Shaking) Cause Correction Refer to Troubleshooting Logic for Engine Cold Engine Running Too Cold. Refer to 35 Idle Speed Too Low for the Check/Adjust Low Idle Screw. Accessories Refer to Page 73 Engine Mounts Over-Tightened, Verify Condition of Mounts.
  • Page 23 Rough Idle (Irregularly Firing Or Engine Shaking)(Continued) Cause Correction Valves Not Sealing Adjust Valves. Refer to Page 179 One or More Cylinders Losing Perform a Compression Check and Repair Compression as Required. Refer to Page 160 A Series Diesel Engine Troubleshooting Logic...
  • Page 24 Engine Runs Rough Or Misfiring Cause Correction Inspect/Correct Leaks in the High Pressure Lines, Fittings Injector Sealing Fuel Injection Lines Leaking Washers, or Delivery Valve. Refer to Page Check the Flow Through the Filter and Air in the Fuel or the Fuel Supply is Bleed the System.
  • Page 25 Engine Runs Rough Or Misfiring (Continued) Cause Correction Replace Injectors. Malfunctioning Injectors Refer to Page 88 Defective Injection Pump Replace Injection Pump. (Delivery Valves) Refer to Page 94 Check/Correct Gear Train Timing Camshaft Out of Time Alignment. Refer to Page 185 Inspect Camshaft.
  • Page 26 Engine RPM will Not Reach Rated Speed Cause Correction Verify High Idle Speed Without Load. Engine Overloaded Investigate Operation to be Sure Correct Gear is Being Used. Verify Engine Speed with Hand Malfunctioning Tachometer Tachometer - Correct as Required. Adjust Linkage for Stop-to-Stop Fuel Throttle Linkage Worn or Control Lever Travel.
  • Page 27 Engine RPM will Not Reach Rated Speed (Continued) Cause Correction If the Condition is Intermittent, Check/Remove Restriction. Restricted Manifold Drain Line Refer to Page 81 Replace Pump. Malfunctioning Injection Pump Refer to Page 94 A Series Diesel Engine Troubleshooting Logic...
  • Page 28 Low Power Cause Correction If the Condition is Slow Throttle Response, Leaking Air Fuel Tighten the Fittings. Replace the Pump if Control Tube or Malfunction the Controls are Not Functioning. Control in the Pump Refer to Page 87 (Automotive Only) Fuel Control Lever Not Moving to Check/Correct for Stop-to-Stop Travel.
  • Page 29 Low Power (Continued) Cause Correction Inspect/Replace Air Cleaner Element. Inadequate, or High or Low Look for Other Restrictions. Temperature Intake Air Refer to Page 112 If the vehicle is equipped with a Valve to Switch the Intake Source from Under the Hood to Outside, Position the Valve for the Season.
  • Page 30 Low Power (Continued) Cause Correction Air Leak Between the Check/Correct Leaks in the Air Crossover Turbocharger and the Intake Tube, Hoses, or Through Holes in the Manifold. Manifold Cover. Refer to Page 100, 101 Check/Correct Leaks in the Manifold or Exhaust Leak at the Manifold or Turbocharger Gaskets.
  • Page 31 Low Power (Continued) Cause Correction Replace Injection Pump. Malfunctioning Injection Pump Refer to Page 94 Check/Correct Exhaust System. Excessive Exhaust Restriction Refer to Page 101 A Series Diesel Engine Troubleshooting Logic...
  • Page 32 Excessive Exhaust Smoke Cause Correction Engine Running Too Cold Refer to Troubleshooting Logic for Coolant (White Smoke) Temperature Below Normal. Inspect/Change Air Cleaner. Look for Inadequate Intake Air Other Restrictions. Refer to Page 112 Air Leak Between the Check/Correct Leaks in the Air Crossover Turbocharger and the Intake Tube, Hoses, or Through Holes in the Manifold Cover.
  • Page 33 Excessive Exhaust Smoke (Continued) Cause Correction Malfunctioning or Over fueled Replace Injection Pump. Injection Pump Refer to Page 94 Piston Rings Not Sealing Perform a Compression Check. Correct as (Blue Smoke) Required. Refer to Page 158 A Series Diesel Engine Troubleshooting Logic...

  • Page 34: Coolant Temperature Above Normal

    Coolant Temperature Above Normal Cause Correction Check/Replenish Coolant. Low Coolant Level Refer to Pages 54 Locate and Correct the Source of the Coolant Leak. Refer to Troubleshooting Logic for Coolant Loss. Incorrect/Malfunctioning Pressure Replace Cap with the Correct Rating for the System.
  • Page 35 Coolant Temperature Above Normal (Continued) Cause Correction Verify that the Gage and Temperature Malfunctioning Temperature Sensor are Accurate. Sensor/Gage Refer to Pages 55 Malfunctioning, Incorrect or No Check/Replace the Thermostat. Thermostat Refer to Page 60, 65 Make Sure the Fill Rate is not Being Air in the Cooling System Exceeded and the Correct Vented Thermostat is Installed.
  • Page 36 Coolant Temperature Above Normal (Continued) Cause Correction Plugged Cooling Passages in Flush the System and Fill with Clean Radiator, Head, Head Gasket or Coolant. Refer to Page 55 Block Verify that the Engine Load Rating is Not Engine Overloaded being Exceeded. Refer to Page 60, 65 A Series Diesel Engine Troubleshooting Logic...

  • Page 37: Coolant Temperature Below Normal

    Coolant Temperature Below Normal Cause Correction Check/Repair Shutters, Fan Clutch, Too Much Air Flow Across the Viscous Fan as Required. Refer to the Radiator Equip. Manufacturer’s Procedure. Incorrect Thermostat, Broken Check/Replace Thermostats. Thermostat Jiggle Pin or Refer to Page 60, 65 Contamination in Thermostat Verify that the Gage and Sensor are Temperature Sensor or Gage...
  • Page 38 Coolant Loss Cause Correction Visually Inspect the Radiator Heater, Radiator or Cab Heater Leaking Hoses and Connections to Locate the Leak. If Oil is Present in the Coolant, Check for a Transmission or Lube Oil Cooler Leak. Visually Inspect the Engine and External Engine Leak Components for Seal or Gasket Leaks.
  • Page 39 Coolant Loss (Continued) Cause Correction Check/Replace the Aftercooler. Look for If the Engine is Aftercooled, After Coolant in the Intake Manifold and in the Cooler Leak Oil. Refer to Page 119 Check/Replace the Oil Cooler. Look for Lube Oil Cooler Leak Coolant in the Oil.

  • Page 40: Lubricating Oil Pressure Low

    Lubricating Oil Pressure Low Cause Correction Check/Replenish Oil. Low Oil Level Refer to Page 116 Check for a Severe External Oil Leak that Could Reduce the Pressure. Verify the Correct Oil is Being Used. Oil Viscosity Thin: Diluted or Check for Oil Dilution. Refer to Wrong Specification Troubleshooting Logic for Contaminated Lube Oil.
  • Page 41 Lubricating Oil Pressure Low (Continued) Cause Correction Check/Replace Cup Plugs. Loose or Missing Cup Plugs Refer to Page 123, 132 Suction Tube Loose or Seal Check/Replace Seal. Leaking Refer to Page 117 Check/Replace Lube Pump. Worn Lube Pump Refer to Page 118, 128 Check/Install New Bearings (s) and Loose Main Bearing Cap Tighten Cap...
  • Page 42 Lubricating Oil Pressure Too High Cause Correction Malfunctioning Pressure Verify the Pressure Switch is Functioning Switch/Gage Correctly. Refer to Page 143 Refer to Troubleshooting Logic for Coolant Engine Running Too Cold Temperature Below Normal. Make Sure the Correct Oil is Being Used. Oil Viscosity Too Thick Refer to O&M Manual.
  • Page 43 Lube Oil Loss Cause Correction Visually Inspect for Oil Leaks. External Leaks Refer to Pages 55. Verify that the Dipstick is Correctly Crankcase Being Overfilled Marked. Incorrect Oil Make Sure the Correct Oil is Being Used. (Specification or Viscosity) Look for Reduced Viscosity from Dilution with Fuel.
  • Page 44 Lube Oil Loss (Continued) Cause Correction Check the Breather Tube Area for Signs of High Blowby Forcing Oil Out the Oil Loss. Measure the Blowby and Breather Perform the Required Repairs. Refer to Page 124 Inspect the Air Crossover Tube for Turbocharger Leaking Oil to the Air Evidence of Oil Transfer.
  • Page 45 Contaminated Coolant Cause Correction Rusty Coolant, Operation Without Drain and Flush the Cooling System. Fill Correct Mixture of Antifreeze and with Correct Mixture of Antifreeze and Water Water. Refer to Page 55. Review the Coolant Change Interval. If Equipped, Leaking Transmission Check/Replace Oil Cooler.
  • Page 46 Contaminated Lube Oil Cause Correction Coolant in the Oil, Internal Engine Refer to Troubleshooting Logic for Coolant Component Leaks Loss Excessive Oil Sludge Review Oil and Filter Change Intervals Make Sure the Correct Oil is Being Used. Review the Operation for Excessive Idling Fuel in the Oil, Engine Operating Resulting in the Engine Running Below Too Cold...
  • Page 47 Fuel Or Oil Leaking From Exhaust Manifold Cause Correction Check/Replace Filter Element. Intake Air Restriction Refer to Page 105 Review Operation for Excessive Idling. Locate and Replace Malfunctioning Injector Needle Valve Stuck Open Injector Obstructed Turbocharger Drain Check/Clean Line. Line Refer to Page 102 Check/Replace Turbocharger.
  • Page 48 Compression Knocks Cause Correction Bleed the Fuel System. Air in the Fuel System Refer to Page 83. Verify by Operating from a Temporary Poor Quality Fuel Tank with Good Fuel; Clean and Flush the Fuel Supply Tanks. Verify that Engine Load Rating is Not Engine Overloaded Being Exceeded.

  • Page 49: Excessive Fuel Consumption

    Excessive Fuel Consumption Cause Correction Check/Repair Accessories and Vehicle Additional Loading form Components. Refer to the Equipment Malfunctioning Accessories Manufacturer’s Procedures. Review Operation for Correct Gear Shifts, Operator Technique Deceleration, and Idling. Make Sure Quality No. 2 Fuel is Being Poor, Quality Fuel Used.
  • Page 50 Excessive Fuel Consumption (Continued) Cause Correction Stop the Engine Mechanically with Lever on the Fuel Pump. Check/Replace Sealing Fuel Shutoff Valve Inoperative Washer, Piston and Spring. Refer to Page 75 Engine Running on Fumes Drawn Check the Air Intake Ducts for Source of into the Air Intake the Fumes.
  • Page 51 Excessive Vibration Cause Correction Refer to Troubleshooting Logic for Rough Engine Not Running Smoothly Running or Misfiring. Check/Replace Engine Mounts. Refer to Loose or Broken Engine Mounts the Equipment Manufacturer’s Service Instructions. Check/Replace the Vibrating Component. Damaged Fan or Malfunctioning Refer to the Equipment Manufacturer’s Accessories Service Instructions.
  • Page 52 Excessive Vibration (Continued) Cause Correction Inspect the Crankshaft and Rods for Loose or Broken Power Damage That Cause and Unbalance. Component Refer to Page 199 Worn or Unbalanced Drive Line Check/Repair According to the Component Equipment’s Manufacturer’s Procedures. A Series Diesel Engine Troubleshooting Logic...
  • Page 53 Excessive Engine Noises Cause Correction Drive Belt Squeal, Insufficient Check the Tensioner and Inspect the Drive Tension or Abnormally High Belt. Make Sure Water Pump, Tensioner Loading Pulley, Fan Hub and Alternator Turn Freely. Check the Tension of Accessory Drive Belts.
  • Page 54 Alternator Not Charging Or Insufficient Charging Cause Correction Loose or Corroded Battery Clean/Tighten Battery Connections. Connections Refer to Page 137 Check/Replace Belt Tensioner. Alternator Belt Slipping Refer to Page 62 Alternator Pulley Loose on Shaft Tighten Pulley. Replace Alternator. Malfunctioning Alternator Refer to Page 144 A Series Diesel Engine Troubleshooting Logic...

  • Page 55: Coolant System

    Coolant System Coolant System Component and Flow The following illustration identifies the significant features of the coolant system. Coolant is drawn from the radiator by the integrally mounted water pump. The output from the water pump empties into the oil cooler cavity of the cylinder block.
  • Page 56 Cooling System Specifications A2300 Coolant Capacity (Engine Only) - Liter [U.S. Qts.].. 3.0 [3.2] Standard Modulating Thermostat – Range – °C [°F] 71 [160] to 85 [185] Coolant System Malfunctions - Diagnosis – The function of the coolant system is to maintain a specified operating temperature of the engine.
  • Page 57 The system is designed to use a specific quantity of coolant. If the coolant level is low, the engine will run hot. The engine or system has a leak if frequent addition of coolant is necessary. Find and repair the leak. Caution : The engine coolant passages must be completely filled with coolant.

  • Page 58: Pressure Caps

    Caution : The small holes in the head gasket are especially susceptible to plugging. Water will cause rust formation reducing the flow in the smaller coolant passages. Caution : These holes are orifices and their size is critical. Do not enlarge the size of the orifices.

  • Page 59: Water(Coolant) Pump

    Air in the coolant can result in loss from the overflow when the aerated coolant is hot. The heated air expands, increasing the pressure in the system causing the cap to open. Similarly, coolant can be displaced through the overflow if the head gasket leaks compression gasses to the coolant system.
  • Page 60 The coolant flow can also be reduced if the inlet hose to the water pump collapses. A hose will usually not collapse while the engine is running at low speed. Check the hose while the engine is running at rated speed.
  • Page 61 If the fan is belt driven, a slipping belt will result in a slower fan speed and reduced cooling. A malfunctioning belt tensioner can be the problem. Note : Check the bearings in the fan hub and other pulleys to make sure they are not causing excessive blet vibration and slippage.

  • Page 62: Thermostat

    An incorrect fan shroud or obstructions can reduce airflow and cause the engine to run hot. Note : Check to be sure air is not recirculating. Check for missing baffles. Thermostat The thermostat controls the coolant temperature. When the coolant temperature is below the operating range, coolant is bypassed back to the inlet of the water pump.

  • Page 63: Gauges, Overfueling And Laoding

    Gauges, Overfueling and Loading Gauges and sensors are used in the system to measure the coolant temperature. These can malfunction and provide an incorrect temperature indication. Caution : Overfueling can cause the engine to overheat. Make sure that the fuel pump is calibrated correctly.

  • Page 64: Cooling System Replacement Procedures

    Cooling System Replacement Procedures Drive Belt – Replacement 12mm Lift the tensioner to remove and install the drive belt. Belt Tensioner – Replacement Preparatory Step: Remove the drive belt 12mm Remove the capscrew and replace the tensioner. Torque Valve: 25.5 Nm [19ft-lbs] Fan Pulley –...

  • Page 65: Fan Hub Replacement

    12mm Remove the four capscrews, fan and spacer. Replace the fan pulley. Torque Valve: 25.5 Nm [19ft-lbs] Fan Hub – Replacement Preparatory Steps: Remove the drive belt. Remove the fan pulley. 12mm Remove the four capscrews and replace the fan hub.

  • Page 66: Water Pump Replacement

    Water Pump – Replacement Preparatory Steps: Drain the coolant. Remove the drive belt. 12mm Remove the four capscrews and water pump, and complete the following steps. Clean the sealing surface on the cylinder block. Install the new gasket. A Series Diesel Engine Coolant System...
  • Page 67 12mm Install the water pump. Torque Valve: 25.5 Nm [19ft-lbs] Thermostat - Replacement Preparatory Steps: Drain the coolant. Remove the drive belt. Disconnect negative battery cable. Disconnect the upper radiator hose. 12mm Note : Loosen the alternator link capscrew and complete the following steps.
  • Page 68 12mm Remove the thermostat housing, lifting bracket and thermostat. Clean the mating surfaces. Position the rubber seal as shown for reassembly. A Series Diesel Engine Coolant System...

  • Page 69: Cup Plug Replacement

    Assemble the removed parts in the reverse order of removal. Torque Valve: (Alternator Link) 25.5 Nm [19 ft-lbs] (Alternator Mounting) 49Nm [37 ft-lbs] (Thermostat Mounting) 25.5 Nm [19 ft-lbs] Cup Plugs – Replacement Remove the cup plugs from the coolant passages as shown.

  • Page 70: Fuel System

    Fuel System Fuel System Component and Flow The following illustration identifies the components of the fuel system. 1. Fuel Injection Pump. 2. Overflow Valve. 3. Fuel Shut-Off Solenoid. 4. Fuel Injection Nozzle. 5. Fuel Tank. 6. Water in Fuel Sensor (WIF). 7. Fuel Filter. 8. Hand Priming Pump Most of the engines will be quipped with a cam–...

  • Page 71: Fuel System Malfunction Diagnosis

    Fuel System Malfunction – Diagnosis The function of the fuel system is to inject clean, atomized fuel into the engine cylinders at a precise time near the end of the compression stroke of each piston. The components of the system contribute to the delivery of fuel to the cylinders.

  • Page 72: Air In The Fuel System

    Air In the Fuel System A replacement of supply lines, fuel filters, injection pump, high pressure lines and injectors will let air enter the fuel system. Follow the specified procedure to bleed the air from the system. Since the lift pump provides a positive pressure through the fuel filter and supply line to the injection pump, loose connections or defective seals will show as a fuel leak.

  • Page 73: Fuel Water Separator/Filter Unit

    Fuel Water Separator/Filter Unit Caution : Be sure to use the correct element. Filtration and separation of water from the fuel is important for trouble-free operation and long life of the fuel system. Some of the clearances between the pump parts are very close. For this reason the parts can easily be damaged by rust formation and contaminants.

  • Page 74: Injection Pump

    Injection Pump The injection pumps are rotary distributor pumps. These pumps perform the four basic functions of: Producing the high fuel pressure required for injection. Metering the exact amount of fuel for each injection cycle. Distributing the high pressure, metered fuel to each cylinder at the precise time.

  • Page 75: Fuel Control Lever Travel And Adjustment

    Fuel Control Lever Travel and Adjustment The amount of fuel injected and subsequently the speed and power from the engine is controlled by the fuel control lever. Restricted travel of the lever can cause low power. Always check for full travel of the lever when diagnosing a low power complaint.

  • Page 76: Manual Shut Down Levers

    Caution : The fuel control lever on the Robert Bosch VE pump is indexed to the shaft during pump calibration. If the lever has been removed and reinstalled incorrectly, engine speed and power will be affected. Manual Shut Down Levers Injection pumps are equipped with mechanical shut down levers.

  • Page 77: Electrical Shut Off Valves

    Electrical Shut Off Valves The injection pumps are equipped with electrical shut off valves. These solenoid-operated valves block the supply of fuel to the high pressure pumping and distribution components. The Robert Bosch VE shut off valve is located at the top, rear of the pump.
  • Page 78 The Robert Bosch valve does not make a very audible sound when actuated, but it can be checked with an ohmmeter for the following values: Robert Bosch Resistance Peak Shut Down Ohms Amperes Values 12 Volt 7.4 + 0.5 Caution : Do not connect the electrical wire to the solenoid when the plunger has been removed.

  • Page 79: Injection Pump Timing

    Injection Pump Timing Pump to engine timing is extremely critical. Pump timing that is off by only a few crankshaft degrees will cause: 1. Poor performance – starting and power 2. Excessive smoke and emission 3. Poor fuel economy Engine pump timing begins with the timing of the injection pump drive gear to the camshaft gear.

  • Page 80: High Pressure Fuel Line

    High Pressure Fuel Line Caution : The high pressure lines must be clamped securely and routed so they do not contact each other or any other component. The high pressure fuel lines are designed and manufactured to deliver fuel at injection pressure to the injectors.

  • Page 81: Injectors

    Warning : The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious bodily harm. Use cardboard to check for cracks and leaks. With the engine running, move the cardboard over the fuel lines and look for fuel spray on the cardboard. Fuel leaks can cause poor engine performance.
  • Page 82 During the injection cycle, high pressure from the injection pump rises to the operating (pop) pressure which causes the needle valve in the injector to lift. Fuel is then injected into the cylinder. A shimmed spring is used to force the needle valve closed as the injection pressure drops belowe the pop pressure to seal off the nozzle after injection.

  • Page 83: Fuel Drain Manifold

    Carbon build up in the orifices in the nozzle will also cause low power from the engine. Remove and check the spray pattern or replace the injectors. Fuel Drain Manifold The fuel system is designed to use fuel to cool and lubricate the injection pump and injectors.
  • Page 84 Fuel System Replacement Procedure A certain amount of air will be entrapped in the system during replacement of any of the system components. After replacement of a component, bleed the system according to the following procedure. Fuel System – Bleeding Controlled venting is provided at the injection pump through the fuel drain manifold.
  • Page 85 High Pressure Lines – Venting 17mm Warning : The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious bodily harm. Loosen the fittings at the injector, and crank the engine to allow entrapped air to bleed from the line. Tighten the fittings.
  • Page 86 Fill the new filter(s) with clean fuel. Lubricate the seal with clean oil. Install the filter(s) and tighten it 1/2 turn after its seal contacts the filter head. A Series Diesel Engine Fuel System...
  • Page 87 High Pressure Lines – Replacement 17mm Disconnect the high pressure lines from the injectors and complete the following steps. A Series Diesel Engine Fuel System...
  • Page 88 10mm Remove the line clamp capscrew from the intake cover. 14mm and 17mm Remove the lines from the injection pump. Note : Use two wrenches to prevent the delivery valve holder from turning. 10mm Assemble the lines in the reverse order of removal. Torque Value: 11Nm [8 ft-lbs] Warning : Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust...
  • Page 89 Fuel Drain Manifold – Replacement 17mm Remove the high pressure fuel line. 17mm Remove the head cap nuts. 17mm Assemble the high pressure fuel line and fuel drain manifold in the reverse order of disassembly. Torque Value: 49Nm [37 ft-lbs] A Series Diesel Engine Fuel System...
  • Page 90 Injector – Replacement Preparatory Steps: Disconnect the high pressure fuel supply lines Disconnect the fuel drain manifold. Clean around the injectors. Rust Penetrating Solvent Caution : When rust has formed on the hold down nut, the injector can turn in the bore when the nut is loosed.
  • Page 91 Injector Bore Brush Clean the injector nozzle bore. Assemble the injector and new copper sealing washer. Use Only One Copper Washer. Apply a coat of anti-seize compound to the threads of the injector hold-down nut and between the top of the nut and injector body.
  • Page 92 Assemble the fuel drain manifold and high pressure lines. Leave the high pressure fittings loose at the injectors. 17mm Warning : It is necessary to put the engine in the “run” position: Because the engine may start, be sure to follow all the safety precautions.
  • Page 93 24mm Remove the valve. Note : The Bosch VE valve is shown. Caution : When removing the valve, be careful not to drop the plunger and spring. “Package” the solenoid, o-ring, spring and plunger. 24mm Tighten the solenoid securely. Connect the electric wire. Torque Value: 20 Nm [15 ft-lbs] A Series Diesel Engine Fuel System...
  • Page 94 Delivery Valve Holder and Sealing Washer (Bosch VE) – Replacement 14mm and 17mm Disconnect the high pressure line. 14mm Remove the delivery valve holder and sealing washer. Insert the sealing washer(1) and the delivery valve(2) in the pump. Insert the ship(4) and spring(3) in the holder(5).
  • Page 95 14mm and 17mm Connect the high pressure lines. 17mm Start the engine and vent one line at a time until the engine runs smoothly. A Series Diesel Engine Fuel System...
  • Page 96 External Pump Leaks Check for excessive flow in the injection pump and fuel line due to leakage Removal (Injection Pump) Caution : Do not drop the nut and washer inside gear housing or engine damage can occur. 12mm Remove the retaining nuts on the fuel injection pump mounting on the rear of the gear housing.
  • Page 97 Installation (Injection Pump) The pump shaft is keyed to the gear, and the gear has timing mark “B” for alignment to the idler gear mark “B”. In order to make sure that the fuel pump key is aligned properly to the gear keyway; rotate the engine opposite engine rotation (counterclockwise) several degrees to put the keyway in the gear approximately at 9:00 o'clock position.
  • Page 98 Timing Dial Indicator Method Find number 1 or top dead center (TDC) on compression for the number 1 cylinder by barring the engine until the hashmarks on the crank pulley line up with the indicator mark on the gear cover. This can be confirmed by removing the front cover access plate and ensuring that the idler gear and fuel pump gear timing marks are aligned.
  • Page 99 Bar the crankshaft in the direction opposite engine rotation until the indicator needle stops moving. Adjust the indicator face to read zero. Rotate the crankshaft in direction of engine rotation back to the mark on the crank pulley. This is the number 1 or top dead center (TDC) mark.

  • Page 100: Air System

    Air System Air System Flow The engines are available in naturally aspirated, turbocharged. Air is pulled into the engine from an air filter. Clean air is very important to the life of the engine. Ingested dust and dirt can damaged the cylinders very quickly. Caution : Make sure that a quality air cleaner is used and that it is periodically replaced according to the manufacturer’s...

  • Page 101: Diagnosing Air System Malfunctions

    Intake Air, Exhaust and A2300 Fuel System Intake Restriction at Rated Speed and Load with Dirty Air 6.23 [635] Filter Element – kPa [mmAq] Exhaust Restriction at Rated Speed and Load – kPa [mmAq] 7.65 [780] Diagnosing Air System Malfunctions The correct amount of clean air to the cylinders is required for good performance.

  • Page 102: Damage From Non-Filtered Air

    Damage From Non-Filtered Air Loose connections or cracks in the suction side of the intake pipe can allow debris to be ingested by the engine causing rapid wear in the cylinders. Leaks at the intake manifold, unsealed bolt holes or manifold cover gasket can also all dust and dir to be ingested into naturally aspirated engines.

  • Page 103: Exhaust Leaks

    In addition to the visual inspection for cracks and loose fittings, liquid soap can be applied to the crossover tube, connections and the manifold cover sealing surfaces to find the leaks. The leaks will create bubbles that are easier to detect. Measurement of manifold pressure is described in this Section.

  • Page 104: Oil Consumption And Leaks

    Oil Consumption and Leaks Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger. The oil is supplied to the turbocharger through the supply line is at engine operating pressure. A return line connected to the bottom of the turbocharger routes the oil back to the engine oil pan.

  • Page 105: Turbocharger Noise

    To verify oil leakage past the seals, remove the exhaust pipe and crossover tube and look for oil in the turbine casing and the crossover tube. Locate and correct the restriction as previously discussed. Turbocharger Noise It is normal for the turbocharger to emit a “whine” sound that varies in intensity depending on engine speed and load.

  • Page 106: Rotor Assembly Clearance Measure

    Lower pitch sounds or rattles at slower engine speeds can indicate debris in the system or the rotor assembly is touching the housings. Rotor Assembly Clearance – Measure Measure the shaft end play. End Play (a) Inch 0.03 0.001 0.06 0.0024 Measure radial clearance of the shaft.
  • Page 107 Air System Replacement Procedures Air Crossover Tube – Replacement Loosen the hose clamps and position the hose so the crossover tube can be remove. Use a new gasket and new hoses and clamps as required to install the air crossover tube. Torque Value: Hose Clamps: 39 Nm [29 ft-lbs] Intake Manifold Cover and Gasket –...
  • Page 108 12mm Remove the manifold cover and complete the following steps. Caution : Keep the gasket material and any other material out of the air intake. Clean the sealing surface. 12mm Install the gasket and cover. Torque Value : 25.5Nm [19 ft-lbs] A Series Diesel Engine Air System...
  • Page 109 Assemble the intake piping and connect the cold starting aid. Install and bleed the high pressure fuel lines. A Series Diesel Engine Air System...
  • Page 110 Turbocharger – Replacement Preparatory Steps: Remove the air crossover tube. Disconnect the intake and exhaust piping. 10mm Remove the oil drain tube capscrews and complete the following steps. 14mm Remove the oil supply line. A Series Diesel Engine Air System...
  • Page 111 12mm Remove the turbocharger. Caution : If the turbocharger is not to be installed immediately, cover the opening to prevent material from falling into the manifold. Clean and inspect the sealing surface. Install a new gasket and apply antiseize compound to the mounting studs.
  • Page 112 Install the turbocharger and connect the air crossover tube. Torque Value : 39Nm [29 ft-lbs] 12mm Use a new gasket and connect drain line. Torque Value : 25.5Nm [19 ft-lbs] Caution : New turbochargers must be prelubricated before start up. Pour 30 to 40cc of oil into supply fitting.
  • Page 113 Exhaust Manifold and/or Gasket - Replacement Preparatory Steps: Remove the air crossover tube. Disconnect the air intake and exhaust piping. Remove the turbocharger and gasket. 12mm Remove the manifold and gasket. Clean the sealing surface. 12mm Install the manifold and gaskets. Torque Value : 25.5Nm [19 ft-lbs] Follow the sequence shown in the illustration.

  • Page 114: Intake Air Restriction

    Install the turbocharger, air crossover tube, oil drain tube, oil supply line, and the exhaust and intake piping. Operate the engine to check for leaks. Intake Air Restriction Replace the air cleaner element when the restriction reaches the maximum limit at rated engine RPM. Naturally Aspirated Turbocharged 6.23 kPa [635 mmAq]...

  • Page 115: Lubricating System

    Lubricating System Lubricating Oil Pump Lubricating System Flow The engine use trochoid type oil pumps (1). The machined cavity in the block is the same for all engines. Pressure Regulating Valve The pressure regulating valve (2) is designed to keep the oil pressure from exceeding 343 kPa [50 PSI].

  • Page 116: Oil Coolers

    Oil Coolers The engines use full flow, plate type oil coolers. The oil flows through a cast passage in the cooler cover and through the element where it is cooled by engine coolant flowing past the plates of the element. The use of incorrect components can cause high or low oil temperature, varnish and sludge build up.
  • Page 117 The main bearings and the valve train are lubricated Lubrication for the valve train is supplied through by pressurized oil directly from the main oil rifle. The separate drillings in the cylinder block. The oil flows other power components, connecting rods, pistons, through the drillings and across the oil transfer slot in and camshaft receive pressurized oil indirectly from the cylinder head gasket.

  • Page 118: Low Oil Pressure

    Diagnosing Lubricating System Malfunctions Be sure to check items related to oil pressure, such as: gauges, high and low oil level, excessive oil contamination, oil viscosity, etc. High Oil Pressure High oil pressure usually occurs after the engine is first started in cold weather.

  • Page 119: Oil Filter

    Oil Filter A plugged filter will cause a gradual loss of pressure by approximately 69 kPa [10 PSI]. The pressure will return to normal when the filter bypass valve opens. Oil Gauge Check the oil gauge and sending unit to make sure they are operating correctly by verifying the pressure with a manual gauge.

  • Page 120: Incorrect Oil Pump

    Incorrect Oil Pump If low or high pressure occurs after changing the pump, verify that the correct pump was used. Oil Dilution Caution: Diluted oil can cause severe engine damage. Check the condition of the oil Thin, black oil is an indication of fuel in the oil.

  • Page 121: Fuel Diluted Oil

    During operation the oil pressure will be higher than coolant pressure. A leak in the oil cooler will show as oil in the coolant. However, following an engine shutdown, the residual pressure in the coolant system can cause coolant to seep through the leak path into the oil.
  • Page 122 Use the following logic to determine the source of the oil dilution with fuel: Power Low – Increased White Smoke Power Low – Increased Black Smoke During Start Up - Verify the Rings are Sealing by Check/Replace the Injectors Performing a Compression Check A worn or damaged injection pump shaft seal will allow fuel to leak into the gear housing and then into the oil pan.
  • Page 123 The bushing (2) in the Bosch VE pump can causes a seal leak. If the bushing is loose in the housing it will move toward the seal raising the lip (1) and providing a leak path for fuel. To check for such a leak remove the fuel drain manifold connection (1) at the pump and install a plug (2).
  • Page 124 Incomplete combustion in the cylinders can result in unburned fuel draining into the oil pan. This condition can be caused by a leaking injector or reduced compression caused by inadequate piston ring sealing. An increase in white exhaust smoke during the first start of the day is a symptom that an injector is leaking.

  • Page 125: Oil Leaks

    Another remote possibility is a crack or porosity in the head casting could allow fuel to leak to the air intake and on to the cylinders. Oil Leaks Various gaskets, seals and plugs are used to contain the oil. Most leaks can be identified during routine inspection of the engine and vehicle.
  • Page 126 If the oil cooler element ruptures, the oil pressure will force oil into the coolant system. Oil in the coolant should be visible when the radiator cap is removed. Worn or damaged seal sin the turbocharger can also allow oil to leak into the air crossover pipe and be burned in the engine.
  • Page 127 Lubricating System Replacement Procedures Oil Pressure Regulator Valve and/or Spring Replacement 24mm Remove the plug and valve. Clean and inspect the plunger, bore and seat before assembly. Note : The plunger must move freely in the valve bore. Assemble the vale in the reverse order of disassembly. Torque Value : 69Nm [51 ft-lbs] Oil Cooler Element and/or Gasket –...
  • Page 128 Fill the coolant system and operate the engine to check for leaks. Stop the engine and check the coolant and oil level. Oil Pan, Suction Tube and/or Gaskets – Replacement 17mm Drain the oil and remove the pan and gasket. 12mm Caution : Be sure to connect the support bracket.
  • Page 129 12mm Install the pan and gasket. Torque Value: 25.5Nm [19 ft-lbs] 17mm Install the drain plug. Torque Value: 78 Nm [59 ft-lbs] Fill the engine with oil. Run the engine and check for leaks. Stop the engine and check the oil level with the dipstick.
  • Page 130 19mm Remove the crankshaft pulley. 12mm Remove the front cover. Remove the Lubricating Oil Pump 5mm Hex Lench Remove the four mounting capscrews. Remove the pump from the bore in the cylinder block. Clean and Inspect If the pump is to be inspected for reuse, follow these steps.
  • Page 131 Installing the Lubricating Oil Pump Lubricate the pump with clean engine oil. Note : Filling the pump with oil during installation will help to prime the pump at engine start up. A Series Diesel Engine Lubricating System Flow...
  • Page 132 12mm Install a new gasket. Tighten in the sequence shown. Torque Value : 25.5Nm [19 ft-lbs] Note : Be sure the gear backlash is correct if installing a new pump. Measure gear backlash. Backlash Limits 0.11 to 0.19mm [0.0043 to 0.0075 inch Note : If the adjusting gear moves when you measure the backlash, the reading will be incorrect.
  • Page 133 Gear Cover – Installation Lubricate the front gear train with clean engine oil. Caution : The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. Thoroughly clean the front seal area of the crankshaft. 12mm Install the front cover and gasket.
  • Page 134 19mm Install the crankshaft pulley 19mm Torque Value : 113Nm [98 ft-lbs] Cup Plugs – Replacement Remove the cup plugs from the oil passages. A Series Diesel Engine Lubricating System Flow...
  • Page 135 To Install the Cup Plugs Apply a bead of Loctite 277 around the outside diameter of the oil passage cup plugs. Drive the cup plugs in until they bottom in the bore. Fill the engine with oil. Run the engine and check for leaks.

  • Page 136: Electrical System

    Electrical System Densko Poongsung 12V 2.0kw Starting Motor Electrical System Description/Operation The electrical system basically consists of the starting motor and the alternator. The injection pump uses an electrical fuel shut off valve. The function of the valve was discussed in the fuel system section.
  • Page 137 Injection Pump Fuel Shut Off Valve Oil Pressure Switch and Temperature Sensors A Series Diesel Engine Electrical System...

  • Page 138: Electrical System Spec

    Electrical System Spec. Minimum Recommended Battery : 12 V –75A Starter Motor: 12V – 2.0kW Alternator: 12V – 45A A Series Diesel Engine Electrical System...

  • Page 139: Starting Motor

    Diagnosing Electrical Malfunctions Starting Motor Before you troubleshoot the starting motor, make sure the battery terminals are not loose or corroded. Engine Does Not Crank If the solenoid does not make an audible sound, check for loose wiring connections. Check the voltage at the solenoid battery post. No voltage –...
  • Page 140 If no voltage is indicated at the S terminal, check: Fuses Voltages to the ignition switch And, if the vehicle is so equipped, voltage to clutch switch, neutral safety switch and engine safety shutoff system. If the solenoid does make an audible sound, turn the switch off and attempt to bar the engine in both directions.

  • Page 141: Engine Cranking Speed Too Slow

    Engine Cranking Speed Too Slow Make sure the wiring connections are clean, tight and not damaged. Check the battery voltages. If the engine was not rotated to check the starting motor (page 7-8), bar the engine in the direction of engine rotation to make sure the engine is free and does not have an internal malfunction.

  • Page 142: Alternator

    Alternator The terminals on the alternator are shown in this illustration. The “R” terminal provides one-half system voltage and is used to operate accessories such as the tachometer on generator sets. Trouble with the charging system may be indicated by the indicator lamp or ammeter.
  • Page 143 If the lamp goes out, there is a short in the switch. Switch On, Lamp Off, Engine Stopped The condition can be caused by an open in the circuit. To determine where an open exists. Check for a blown fuse, a burned out bulb, defective bulb socket, or an open in No.
  • Page 144 If the lamp goes out, replace the alternator. Abnormal Charging System Operation Check the battery and all wiring connections. Inspect the wiring for defects. Check all connections for tightness and cleanliness, including the slip connectors at the alternator and firewall, and connections at the battery. With ignition switch on and all wiring harness leads connected, connect a voltmeter from: Alternator “BAT”...

  • Page 145: Fuel Shut Off Valve Check

    Fuel Shutoff Valve – Check Note : Check all connections for loose or corroded connections for broken wires. Remove the valve. Ground the valve and connect 12 volts DC to the terminal and observe plunger movement. Oil Pressure Switch and Temperature Sensor When diagnosing problems with either the pressure switch or the temperature sensor, check for loose or...
  • Page 146 Engine Electrical System Replacement Procedures Starting Motor - Replacement Preparatory Steps: Disconnect the ground cable from the battery terminal. Identify each electrical wire with a tag indicating location. 12mm Remove the battery cable from the solenoid. 17mm Remove the starting motor. Install the starting motor in the reverse order of removal.
  • Page 147 12mm Remove the alternator bolts. 14mm Remove the alternator mounting nuts. 12mm, 14mm Install the alternator by tightening the 12mm bolts before the 14mm bolts. Reconnect all wires. Torque Value : (12mm) 25.5Nm [19 ft-lbs] .(14mm) 49Nm [37 ft-lbs] A Series Diesel Engine Electrical System...
  • Page 148 Electric Fuel Shut Off Valve - Replacement Remove the electrical wire(s) and complete the following steps. 24mm Caution : When removing the valve, be careful not to drop the piston and spring. Clean around the valve. Replace the valve and connect the electrical wire. Oil Pressure Switch –...
  • Page 149 Temperature Sensor – Replacement Preparatory Step: Drain coolant Disconnect the temperature sensor wiring. 17mm Remove the temperature sensor. 17mm Apply liquid Teflon sealant to the threads when installing the temperature sensor. Reconnect the wiring. Torque Value: (Installed into Aluminum) 39Nm [29 ft-lbs] A Series Diesel Engine Electrical System...

  • Page 150: Operation And Description

    Base Engine Components Operation and Description This section of the manual defines the base engine components, describes the operation of those components, provides guidelines for diagnosing malfunctions and gives procedures for component replacement and in-chassis overhaul. Definition For the purpose of this manual, Base Engine Components are defined as mechanical functions not included in the other major engine systems.

  • Page 151: Cylinder Head And Valve Train

    Cylinder Head and Valve Train The cylinder head is a one piece, crossflow design with two valves per cylinder. The head has integrally steel alloy valve guides and hardened valve seat surfaces which can be repaired in a machine shop using the appropriate service parts. The cylinder head has a cast intake manifold, fuel filter head, thermostat housing and an internal water bypass.

  • Page 152: Front Gear Housing And Gear Train

    Front Gear Housing and Gear Train The gear train consists of the crankshaft gear, lube pump gear idler, the camshaft gear, the fuel pump gear and the accessory drive gear, if used. The gear housing provides a support for the injection pump, and the accessory drive gear, if used.

  • Page 153: Flywheel Housing And Flywheel

    The camshaft has lobes to operate the intake and exhaust valves. The valve lobes contact “mushroom” shaped valve tappets which operate the push rods. The profile of the cam lobes is the same for all A series engines. The tappets are mushroom shaped. The convex shape of the surface which contacts the camshaft lobe causes the tappet to rotate as it lifts the push rod.

  • Page 154: Piston And Rod Assemblies

    Piston and Rod Assemblies Piston features include : high swirl combustion bowl cast aluminum body and 3 ring grooves. Always check the part number to be sure the correct configuration is used during piston replacement. The piston ring sets are also different. While both sets consist of three rings;...
  • Page 155 The connecting rod is made of high-strength gorged carbon-steel. The large end with the special aluminum-ally metal can be separated into two and the small end has a copper alloy coil bushing. Oversize service rod bearings are available for use with re- ground crankshafts.

  • Page 156: Crankshaft And Main Bearings

    Crankshaft and Main Bearings The crankshaft is a balanced, forged steel unit. Four cylinder engines have a main bearing. The lower bearing shells are all the same. All of the upper bearing shells are all the same. The two thrust bearings control the end thrust of the crankshaft.
  • Page 157 The cylinder bores are machined directly into the block during production. The size and condition of the bore is critical to engine performance and life. During repair, be sure to inspect the bore carefully. Cylinder liner can be replaced into cylinder block. Both cylinder and liner have size mark on.

  • Page 158: Oil Pan

    Oil Pan A front sump, rear sump or center sump pan options may be used depending on the application. The mounting of the oil pick up tube will vary with the pan used. Rear Crankshaft Seal The rear crankshaft seal is mounted in a housing that bolts to the rear of the block.

  • Page 159: Air And Fuel System

    Air and Fuel System – Check When diagnosing a low power problem first troubleshoot the air and fuel systems to make sure the engine is receiving adequate intake air and fuel. Check the intake air system for leaks. Make sure a sealant is used on the through-hole capscrews wich secure manifold cover to the head.

  • Page 160: Compression Check

    Compression Check If the air and fuel system are functioning correctly, perform a compression check to determine whether the problem is: Piston ring sealing Valve sealing Head gasket sealing or a crack in the cylinder head Piston Ring Seal If the compression is low but can be increased significantly by squirting oil into the cylinder, the cause of low compression is inadequate sealing between the rings and the cylinder walls.
  • Page 161 Head Gasket Sealing If the compression was found low on adjacent cylinders and the pressure cannot be increased by oiling the rings, the head gasket is probably leaking between the cylinders. Low compression on a single cylinder can be caused by an external leak or a leak to a coolant passage.

  • Page 162: Valve Seal Wear

    External head gasket leaks can be detected visually. Liquid soap can be used to locate external leaks. Valve Seal – Wear Worn valve seals are typically detected by excessive smoke at idle or when the engine is unloaded when the vehicle is going down hill. Verify the condition by removing the valve spring and inspecting the seals.

  • Page 163: Front Gear Housing And Gear Train

    Front Gear Housing and Gear Train Troubleshooting the front gear housing and gear train consists of checking for leaks at the gaskets (front cover, and injection pump) and the front crankshaft oil seal, inspecting the gears and measuring backlash when required. Gear noise emitted from the cover can indicate worn gear teeth.

  • Page 164: Rocker Levers

    Rocker Lever, Valve Stem, Push Rod, Tappet, and Camshaft Excessive valve lash can indicate a worn valve stem or rocker lever. Loose rocker levers and the need to re-set the valve clearance frequently, can also indicate cam lobe or tappet wear. If an inspection of the levers, valve stems and push rods does not show wear, then tappet and/or cam lobe wear can be suspected.

  • Page 165: Piston And Rod Assembly

    Piston and Rod Assembly There are a number of power relate problems including excessive oil consumption, smoke, blow-by and poor performance that can be caused by inadequate sealing between the piston rings and the cylinder walls. A blow-by measurement can help detect the problem. Verification of the damaged or worn component requires visual/dimensional inspection of rings, pistons and cylinder bore.
  • Page 166 However, it is also critical that the cylinder liner walls be thoroughly cleaned. Grit left in the cylinder wall will cause rapid wear out of the new rings leading to the previously discussed power problems. Overheating of the engine from a loss of coolant will cause the cylinder to overheat resulting in seizure of the piston.

  • Page 167: Crankshaft And Main Bearings

    A rod knock occurs when the engine is not loaded. Verify by first applying load and then unloading and listening for the knock. Crankshaft and Main Bearings Improper maintenance of the lubrication system is also the primary cause of reduced main bearing life. A malfunction of the crankshaft/main bearing will usually be detected by reduced oil pressure.

  • Page 168: Cylinder Block

    Failure of driven units at the front or rear of the engine which increase the end loading can damage the thrust bearing. Cylinder Block Diagnosis of cylinder block malfunctions relative to cooling and lubrication has been discussed in those respective systems. The potential problems with cylinder, the camshaft bore and the crankshaft main journals have also been discussed in this Section.
  • Page 169 Occasional failure of a starter to engage can be caused by damaged teeth on the ring gear. Service ring gears are available for repairing flywheels. When troubleshooting a transmission vibration problem, it may be necessary to measure the concentricity of flywheel housing-to-crankshaft. Note : The following procedure is for use with an indicator whose needle rotates clockwise as the top is depressed.

  • Page 170: Base Engine Componen Specifications

    Base Engine Components Specifications Valve Train Valve Clearance - Intake 0.3mm [0.012 in] - Exhaust 0.3mm [0.012 in] Valve Guide Diameter 8.025 mm [0.316 in] MAX 8.010 mm [0.3153 in] MIN Valve Stem Diameter 7.97 mm [0.3138 in] MAX 7.96 mm [0.3134 in] MIN Valve Seat Angle Intake 30 degrees...

  • Page 171: Gear Train

    Cylinder Head Flatness Total Maximum Overall 0.15 mm [0.006 in] Gear Train Gear Backlash Crankshaft, Injection pump drive, camshaft: 0.07 to 0.15mm [0,0027 to 0.006 in] Oil pump: 0.11 to 0.119mm [0,0043 to 0.0075 in] Camshaft Journal Diameter 44.964 to 44.95 mm [1.7702 to 1.7697 in] Worn Limit: 44.89 mm [1.767 in] Valve Lobes Standard: 37.

  • Page 172: Pistons

    Pistons Skirt Diameter (Minimum) Nominal 87.95 to 87.97 mm [3.463 to 3.4634 in] Worn Limit 87.90 mm [3.46 in] Pin Bore Diameter (Maximum) 30.008 mm [1.181 in] Worn Limit: 30.02 mm [1.1819 in] Note : Measure the diameter on a vertical axis only. Ring Groove (Minimum) Top Groove 2.006 mm [0.079 in]...

  • Page 173: Connecting Rod

    Connecting Rod Pin Bore Diameter MAX: 30.038 mm [1.1823 in] Worn Limit: 30.1 mm [1.185 in] Crankshaft Main Bearing Journal Diameter Standard: 53.964 to 53.95 mm [2.2146 to 2.1240 in] Worn Limit: 53.91 mm [2.122 in] Connecting Rod Journal Standard: 49.964 to 49.95 mm [1.967 to 1.966 in] Worn Limit: 49.91 mm [1.965 in] Cylinder Block...

  • Page 174: Cylinder Bore

    Main Bearing Bore Diameter Standard: 50.0 to 50.045 mm [1.9685 to 1.97 in] Camshaft Bore Diameter (Maximum) Standard: 45.03 to 45.06 mm [1.773 to 1.774 in] Tappet Bore Diameter Standard: 14.26 to 14.28 mm [0.561 to 0.562 in] Cylinder Bore Cylinder Bore Diameter Standard: 88.0 to 88.02 mm [3.464 to 3.465 in]...

  • Page 175: Base Engine Components

    Base Engine Components Replacement Procedures Rocker Lever and Push Rods – Replacement Preparatory Step: 17mm Remove the valve covers. Removal 12mm Loosen the adjusting screw locknuts. Loosen the adjusting screws until they stop. 19mm Remove the 19mm nuts from the rocker lever pedestals.

  • Page 176: Rocker Levers

    Rocker Levers – Disassembly If the rocker lever and push rods are to be inspected for reuse, follow these steps. Remove the retaining rings and thrust washers. Remove the rocker levers. Caution : Do not disassemble the rocker lever shaft and pedestal.
  • Page 177 Clean all parts in a strong solution of laundry detergent in hot water. Use compressed air to dry the parts after rinsing in clean hot water. Note : The pedestals are made from powdered metal and will continue to show wetness after they have been cleaned and dried.
  • Page 178 Inspect the pedestal and shaft. Measure the shaft diameter. Standard: 19.0 to 19.021 mm [0.748 to 0.749 in] Worn Limit: 19.09 mm [0.751 in] Rocker Levers – Assembly Install the adjusting screw and lock nut. Lubricate the shaft with engine oil. A Series Diesel Engine Base Engine Components...
  • Page 179 Position the levers on the rocker shaft. Install the snap rings. Clean the push rods in hot soapy water. A Series Diesel Engine Base Engine Components...
  • Page 180 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Check the push rods for roundness and straightness. Install the push rods into the sockets of the valve tappets.

  • Page 181: Rocker Levers Assembly

    Rocker Lever Assembly – Installation Use clean engine oil to lubricate the threads and under the heads of the 19mm nuts. Install the nuts into the pedestals. Valve Clearance – Adjustment Caution : Adjust the valves when the engine is cold – below 60℃...

  • Page 182: Camshaft And Tappet

    Adjust the valve clearances for intake valves No. 1 and No. 2. Adjust the valve clearances for exhaust valves No. 1 and No. 3. Rotate the crankshaft in the normal direction one revolution. Adjust the valve clearances for intake valves No. 3 and No.

  • Page 183: Camshaft Inspection

    Rotate the engine to align the crankshaft to camshaft timing marks. 12mm Remove the capscrews from the thrust plate. Remove the camshaft and thrust plate. Camshaft Inspection Inspect the lift pump lobe, valve lobes and bearing journals for wear, cracking, pitting and other damage. A Series Diesel Engine Base Engine Components...

  • Page 184: Camshaft Bushing Inspection

    Inspect the gear teeth for wear and damage. Look for cracks at the root of the teeth. Measure the bearing journals and valve lobes. Journal Diameter: Standard: 44.964 to 44.95 mm [1.7702 to 1.7697 in] Worn Limit: 44.89 mm [1.767 in] Camshaft Bushing Inspection Caution : If the bushing is worn beyond the limit, install a new service bushing.

  • Page 185: Tappet Inspection

    Note : Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing. Install the bushing so that it is even with the front face of the cylinder block. Measure the installed bushing.
  • Page 186 Tappet stem specifications Inside Diameter: Standard: 1.4228 to 14.243 mm [0.5601 to 0.5607 in] Camshaft Installation Apply a coat of Lubriplate 105 to the camshaft bores. Lubricate the camshaft lobes, journals and thrust washer with Lubriplate 105. Install the camshaft/thrust washer. Align the timing marks as illustrated.
  • Page 187 Install the thrust washer capscrews and tighten to 25.5Nm [19 ft-lbs]. Verify the camshaft has proper back lash and end play. A = 0.07 to 0.15 mm [0.0027 to 0.0059 in] B = 0.05 to 0.25 mm [0.002 to 0.0098 inch] Complete the installation of the removed parts.

  • Page 188: Gear Housing Or Gasket

    Gear Housing or Gasket – Replacement Preparatory Step: Remove the v-pulley. Remove the gear driven accessory drive if the engine is so equipped. 12mm Remove the gear housing and gasket. Clean the gasket material from the cylinder block. 12mm Caution : If a new housing or other than the original housing is installed, the timing pin assembly must be accurately located.

  • Page 189: Flywheel Ring Gear And Rear Sel

    Flywheel Ring Gear and Rear Seal – Replacement Preparatory Step: Remove the transmission Ring Gear – Replacement 19mm Remove the Flywheel. Brass Drift Pin Warning : Wear eye protection when you drive the gear from the flywheel. Do not use a steel drift pin.

  • Page 190: Flywheel

    Warning : Wear protective glove when you install the heated gear. Install the gear. The gear must be installed so the bevel on the teeth is toward the crankshaft side of the flywheel. Flywheel – Installation Caution : Never use the timing pin to hold the crank- shaft.

  • Page 191: In Chassis Overhaul

    In-Chassis Overhaul The remaining procedures in this manual are organized for an in-chassis overhaul. An in-chassis overhaul includes: Inspecting the turbocharger Replacing piston rings Replacing connecting rod bearings Replacing crankshaft main bearings Grinding valves Testing injectors This manual gives the procedures to replace the piston rings, rod bearing, main bearings and grinding the valves.

  • Page 192: Cylinder Head Removal

    Cylinder Head Removal Drain the coolant and oil Disconnect the radiator and heater hoses Remove the turbocharger and air crossover, if the engine is so equipped Remove the exhaust manifold Remove the fuel lines and injector nozzles Remove the valve covers Remove the rocker levers and push rods Remove the fuel filter 17 mm...

  • Page 193: Main Bearing Preliminary Inspection

    Check the top surface for damage caused by the cylinder head gasket leaking between cylinders. Check the top surface for flatness between each cylinder. Limits Variance: Standard: 0.03 mm [0.0012 in] Worn Limit: 0.15 mm [0.006 in] Note : Do not proceed with the in-chassis overhaul if the cylinder block head surface is damaged or not flat.
  • Page 194 Inspect the journals for deep scratches, indications of overheating and other damage. Note : If the journals or main caps are damaged, the engine will need to be removed to complete the overhaul. Piston and Rod Removal Caution : Make sure the ridge reamer does not make a deep cut into the bore.
  • Page 195 14mm Remove the capscrews, connecting rod cap and bearings. Caution : Use care so that the cylinder bore or connecting rod is not damaged. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. Put the assemblies in a rack for disassembly later.

  • Page 196: Main Bearing

    Caution : Be sure to remove the tape covering the lube holes after the cleaning process is complete. Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is removed.
  • Page 197 Inspect all caps and main bearing crankshaft journals. (refer to page 171) Determine the size of the bearing removed and obtain the same size for installation. Refer to page 171 for the dimensions of the standard and undersize main bearing journals. Caution : Do not lubricate the side that is against the cylinder block.

  • Page 198: Piston And Rod

    Install the lower bearings into the caps. Apply a coat of Lubricate 105 to the bearings. 19mm Caution : The crankshaft must rotate freely. Install a main bearing cap after each upper bearing is installed to keep the bearing in place while the other uppers are installed.

  • Page 199: Piston, Pin And Connecting Rod

    Remove the piston pin. Note : Heating the piston is not required. Remove the piston rings. Piston, Pin and Connecting Rod – Clean Caution : Do not use bead blast to clean the pistons. Soak the pistons in cold parts cleaner. Soaking the pistons overnight will usually loosen the carbon deposits.
  • Page 200 Caution : Do not use a ring groove cleaner and be sure not to scratch the ring-sealing surface in the piston groove. Clean the remaining deposits from the ring grooves with the square end of a broken ring. Wash the pistons again in a detergent solution or solvent.
  • Page 201 Use a new piston ring to measure the clearance in the ring groove. Limits Minimum Clearance Top groove: 2.006 mm [0.079 in] Oil Control: 3.002mm [0.1102 in] Measure the pin bore Diameter 30.008 mm [1.1814 in] Worn Limit: 29.9 mm [1.177 in] Inspect the piston pin for nicks, gouges and excessive wear.
  • Page 202 Measure the pin bore. Maximum Diameter 30.038 mm [1.1826 in] Worn Limit: 30.1 mm [1.185 in] Bearing clearance can also be determined with Plastigage during engine assembly. Piston to Connecting Rod – Installation Caution : Be sure “Front” marking on piston and the numbers on the rod and cap are oriented as illustrated.
  • Page 203 Lubricate the pin and pin bores with engine oil. Install the pin. Note : Pistons do not require heating to install the pin, however, the piston does need to be at room temperature or above. Install the second retaining ring. Determine the piston diameter and obtain the appropriate ring set.

  • Page 204: Piston Ring Gap

    Piston Ring Gap – Check Position each ring in the cylinder and use a position to square it with the bore. A= 20 mm [0.0787 in] Use a feeler gauge to measure the gap. Limits Ring Minimum Maximum Top: 0.20 mm [0.0079 in.] 0.35 mm [0.0138 in.] Intermediate: 0.25mm [0.0100 in.]...
  • Page 205 Position the oil ring expander in the oil control ring groove. Install the oil control ring with the end gap opposite the ends on the expander. Install the intermediate ring. Install the top ring. A Series Diesel Engine Base Engine Components...

  • Page 206: Piston And Rod Assembly

    Position the rings. Determine the size of the removed rod bearing and obtain a set of the same size. Install the new bearings in the rods and caps and lubricate them with a light coat of Lubriplate 105. Piston and Rod Assembly – Installation Lubricate the cylinder bore with clean engine oil.
  • Page 207 Generously lubricate the rings and piston skirts with clean engine oil. 75 to 125mm Ring Compressor Caution : If using a strap-type ring compressor, make sure the inside of the strap does not hook on a ring gap and break the ring. Compress the rings.
  • Page 208 Note : The following series of illustrations show the engine in a vertical position. This is for clarity of illustration only. Use clean engine oil to lubricate the threads and under the heads of the connecting rod capscrews. Caution : The four digit number stamped on the rod and cap at the parting line must match and be installed towards the oil cooler side of the engine.

  • Page 209: Cylinder Head And Gasket

    Caution : Do not measure clearance between the cap and crankshaft. Measure the side clearance between the connecting rod and crankshaft. Side Clearance Limits 0.15 mm 0.35 mm [0.006 in] [0.0138 in] Install the suction tube and oil pan (refer to page 6-19). Cylinder Head and Gasket –...
  • Page 210 Install the push rods and rocker levers (refer to page 179). Lubricate the cylinder head capscrews. Use the illustrated torque sequence. 17mm Torque Value: Step 1 – 29 Nm [22 ft-lbs] Step 2 – 59 Nm [44 ft-lbs] Step 3 – 93 Nm [70 ft-lbs] 19mm Caution: Be sure to lubricate the push rod sockets with clean engine oil.
  • Page 211 Install the parts previously removed: Valve covers Injector nozzles Fuel lines Fuel filters Exhaust manifold Torbocharger, air crossover and aftercooler, if the engine is so equipped. Observe the Following Check List During Final Assembly Correct injectors for the engine rating used and only one copper sealing washer installed? Sealant applied to the capscrews that attach the intake manifold cover or aftercooler? Turbocharger pre-lubed?
  • Page 212 Caution : Stop the engine immediately if any unusual sounds are heard. Start the engine. If necessary, bleed the high pressure lines at the injectors until the engine runs smoothly. Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.

  • Page 213: Cylinder Head

    Cylinder Head – Disassembly The following disassembly and assembly procedures are provided for inspection purposes only. Refer to the Shop Manual, Bulletin No. 3810206, for complete rebuild instructions. Mark the valve to identify their position. Compress the valve spring and remove the valve stem collets.
  • Page 214 Remove the valve stem seals. Cylinder Head – Clean and Inspect Clean the carbon from the injector nozzle seat with a nylon brush. Scrap the gasket material from all gasket surfaces. Wash the cylinder head in hot soapy water solution. After rinsing, use compressed air to dry the cylinder head.
  • Page 215 Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to keep a flat surface. Inspect the valve guides for scuffing or scoring. Measure the valve guide bore. Maximum Diameter 8.025 mm [0.3160 in] Worn Limit: 8.1 mm [0.319 in] Inspect the head surface for nicks, erosion, or any other damage.

  • Page 216: Valves

    Mark the valves again for location in the cylinder head. Inspect for abnormal wear on the heads and stems. Measure the valve stem diameter. Maximum Diameter 7.960mm [0.3134 in] If new valves are required, mark them for location in the cylinder head. Valves –...
  • Page 217 Seat Angle Intake: 30 Degrees Exhaust: 45 Degrees Measure rim thickness. Minimum Thickness (T) Standard: 1.2 mm [0.047 in] Worn Limit: 0.5 mm [0.0197 in] Check the valve stem tip for flatness. If required, re-surface the valve stem tip. A Series Diesel Engine Base Engine Components...

  • Page 218: Valve Seats

    Valve Seats – Grind Note: The illustrated marks indicate valve seat have been ground previously. Previously re-ground seat can be replace with service seats. Calculating the Grinding Depth Install the valves in their designated location and measure valve depth. Note : The valve depth is the distance from the valve face to the head deck.
  • Page 219 Seat Angle Intake: 30 Degrees Exhaust: 45 Degrees Install the valves in their respective bores and measure depth again. Note : Make sure the seats are clean before you measure the depth. Record the depth of each valve as (B). Calculate grinding depth (GD) as follows: GD= (B) –...
  • Page 220 Note : Identify re-ground valve seats. Install the valves in their designated location and measure the depth. Caution: Replace the valve if the depth is over the limit. Check valve depth (C). Valve Depth Standard: 0.69 to 0.70 mm [0.0271 to 0.0279 in] Worn Limit: 1.0 mm [0.0394 in] Apply a light coat of valve lapping compound to each valve and lap each valve to its companion seat.
  • Page 221 Remove the valves and clean lapping compound from the valves and seats. Measure the valve seat width indicated by the lapped surface. Valve Seat Width Limit Intake: Standard: 1.73 mm [0.0681 in] Worn Limit: 2.23 mm [0.088 in] Exhaust: Standard: 2.12 mm [0.083 in] Worn Limit: 2.62 mm [0.103 in] Valve Springs –...

  • Page 222: Cylinder Head

    Cylinder Head – Assembly Note : Clean all cylinder head components before assembling. Install the valve stem seals. Note : The intake and exhaust seals are the same. Lubricate the stems with SAE 90W engine oil before installing the valves. Compress the valve spring after assembling the spring and retainer.

  • Page 223: Hydraulic Pump Drive Gear And Shaft

    Warning : Wear eye protection. If the collets are not correctly installed, they can fly out when the stems are hit with a hammer. After assembly, hit the valve stems with a plastic hammer to make sure that the collets are seated. Hydraulic Pump Drive Gear and Shaft - Inspect for Reuse (Just for D15S/18S/20SC-2)

  • Page 224: Balancer-Install

    Balancer - Install Align the timing marks on the crankshaft drive gear and the balancer driven gear. Install the shim or shim plate (1), balancer, and lightly lubricate the capscrews with clean 15W-40 engine oil. Make sure that the oil supply passage is open and the o-ring (2) is installed..

  • Page 225: Engine Replacement And Testing

    Engine Replacement and Testing Engine Replacement If the engine cannot be repaired in chassis, use the following guidelines for removal and installation of the engine. Caution : Use the equipment manufacturer’s recommendations and precautions for removal of chassis parts to gain access to the engine.
  • Page 226 Disconnect all electrical connections. Put tags on the connections to identify their locations. Disconnect all lines including fuel lines to the lift pump and fuel return. Use tags to identify the lines. Put a cover or tape over all engine openings. Use the lifting eyes to lift the engine.

  • Page 227: Engine Installation

    Engine Installation Caution : Do not exceed the torque value for the engine supports. Check the data plate to verify that the replacement engine is the same model and rating as the engine that was removed. Note : Install all accessories and brackets that had been removed form the previous engine.
  • Page 228 Adjust the length of the cable/rod to the mechanical shut down lever so there is stop-to-stop movement. Note : Make sure the air intake and exhaust pipe connections are tight and free of leaks. Fill the engine with the required amount of lubricating oil.

  • Page 229: Engine Testing

    Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts. Engine Testing Verify engine performance by performing an in-chassis check. Operating Conditions for Run-In and Test Measurement Limit (s) Coolant Temperature ּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּ 100℃ [212℉] Maximum Lubricating Oil Temperature ּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּ...

  • Page 230: Specifications

    Specifications General Engine General Engine Data - A2000, and A2300 Naturally Aspirated Engine Weight (Dry) Less Flywheel and Electronics - A2000 and A2300 203 kg [448 lbs] Compression Ratio 21:1 Bore - A2000 84 mm [3.31 in] - A2300 88 mm [3.46 in]...

  • Page 231: Cooling System

    Cooling System Coolant Capacity (Engine Only) - A2000, and A2300 3 liters [3.2 qt] Standard Modulating Thermostat - Range 71 - 85°C [160 - 185°F] Maximum Allowable Operating Temperature 100°C [212°F] Minimum Recommended Operating Temperature 71°C [160°F] Minimum Recommended Pressure Cap...

  • Page 232: Capscrew Markings And Torque Values

    Capscrew Markings and Torque When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better Values torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb. General information Caution : When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced.
  • Page 233 Capscrew Markings and Torque Values – Metric Body Size Torque Torque Torque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb — — — — — — —...
  • Page 234 Capscrew Markings and Torque Values – U.S Customary Capscrew Cast Iron Aluminum Cast Iron Aluminum Body Size N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb 1/4 - 20 1/4 - 28 5/16 - 18 5/16 - 24 3/8 - 16 3/8 - 24 7/16 - 14 7/16 - 20...

  • Page 235: Fraction, Decimal, Millimeter Conversions

    Fraction, Decimal, Millimeter Conversions Fraction inch Fraction inch 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 37880 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.381 19/32 0.5938...

  • Page 236: Newton-Meter To Foot-Pound Conversions

    Newton-Meter to Foot-Pound Conversions N•m ft-lb N•m ft-lb N•m ft-lb 9 in-lb 44 in-lb 53 in-lb 62 in-lb 71 in-lb 80 in-lb 89 in-lb 97 in-lb 106 in-lb 124 in-lb 133 in-lb 142 in-lb 159 in-lb 15 ft-lb Note : To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803. Pipe Plug Torque Values Size Torque...

  • Page 237: Weights And Measures-Conversion Factors

    Weights and Measures – Conversion Factors From From U.S. Metric Customary Quantity U.S. Customary Metric To U.S. To Metric Customary Multiply By Multiply By Unit Name Abbreviation Unit Name Abbreviation sq. inch sq. millimeters 645.16 0.001550 Area sq. centimeters 6.452 0.155 sq.
  • Page 238 From U.S. From Metric Customary To U.S. Quantity U.S. Customary Metric To Metric Customary Multiply By Multiply By (1.8 x °C) Temperature fahrenheit °F centigrade °C (°F-32) ÷1.8 pound force per foot ft-lb Newton-meter N•m 1.35582 0.737562 Torque pound force per inch in-lb Newton-meter N•m...

  • Page 239: Special Tools

    SPECIAL TOOLS Tool name Style Tool No. ST 434 Vacuum Gauge ST 537 Dial Depth Gauge ST 647 Standard Puller ST 1111-3 Manometer ST 1273 Pressure Gauge A Series Diesel Engine Special Tools...
  • Page 240 Style Tool No. Tool name ST 1325 Dial guage attachment 3162745 Injector/Connector Removal tool 3163292 Valve spring compressor 3375072 Dial bore gauge, kit 3375432 Crack Detection Kit A Series Diesel Engine Special Tools...
  • Page 241 Style Tool No. Tool name 3376579 Tube(Filter) Cutter 3376946 Injector nozzle tester 3377161 Digital multimeter 3377259 Fuel Pump Timing tool 3377462 Digital optical tachometer A Series Diesel Engine Special Tools...
  • Page 242 Style Tool No. Tool name 3822476 Blow By tool, use with ST1111-3 3822666 Digital Thermometer 3823137 Pistion ring expander A Series Diesel Engine Special Tools...

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